Upholstery cushions



Sept. 4, 1956 Q E LENZ 2,761,493

UPHOLSTERY CUSHIONS Filed July 7, 1952 INVENTOR CHA/EL E5 E. L ENZ BY KW ATTORNE Y UPHOLSTERY CUSHONS Charles E. Lenz, Ruxiton, Md. Application July '7, '19.512, Serial 1519.297527 to claims. (c1. s-.179) Y.

This invention relates to upholstery cushions, and more United States Patent "ice particularly t0 100s@ CuShQnS ,for uphelstsred Chairs d avenports, etc.

It has -been the common practice for manyyearsin the manufacture of cushions Vfor furniture to provide ,a core of relatively closely spaced coil 'springs covered byicotton batting or ,similarlyloosely filled material, and toplace the structurethus formed in a fabric covering to formi/the finished cushion. The springs employed in such structures must be anchored in position and tiedto limit their expansion, andthe springsarerelatively expensive to buy and accordingly to install. Numerous efforts have been madeV to. provide a satisfactory substitute core vfor the spring structures referredto, and while a certain degree of successhas been attained, such structures never provided the comfortablewresiliency of 4spring-filled cushions.

This, Cost 0f manufacmrins ,the 'Spins Structures renders. it

even more desirable to lind a substitute fof springfilled cushions. y

An important object of thepresent invention is to provide a novel type of substitute core for the spring structures of spring-filled cushions wherein such substitute core may be relatively easilyvvmanufactured of such material as foam vrubber and which provides the finished cushion with a degree of comfort and resiliency use which is comparable to a spring-filled cushion.l

A vfurther object is to so forma core ofthe character referred to as to provide the highestrdegree of 7Vresiliency `adjaent the points at which the greatest weight is supported by the cushion, namelyy substantially' centrally thereof. Y

A further object is to provide a core stljuctureA as a whole f or cushions comprising a core unit of the [chanac-v ter referred to and a surrounding loose fibrous structure of such nature as to cooperate with the core element to retain the latter in position and substantially to .retain` its own shapeand resiliency over long periods of time.

A further object is to provide such a corestructureasla whole wherein the material surrounding the core element is .in the nature of loosely felted material such as cotton batting, and wherein such structure is so formed as to provide an internal pocket substantially corresponding in shape to the foam rubber core element.

A further object is to provide such a core structure as a whole vwherein the filler material surrounding the foam rubber core element is reinforced by loose stitchingto minimize horizontal elongation of thelayers of which the lillerstructure is formed.

A vfurther object is to yprovide such a filler structure zwherein some -or all of the surfaces of the layers-are lcoated with 1a binding material to increasethe stability of `theflayers ofliller material, thus materially lengthening the life of the cushion, and permitting, if desired, the ship- Aping of the core structure as a whole, without a fabric covering thereon, to furniture manufacturers to be .embodiedby them in a cushion surrounded by a fabric cover- 'atented Sept.V 4, 1.9.56

2 willbecome apparent during the course of thefollowing description.' Y

In thedrawing, I have shown one embodiment invention. In this showing,"

Figure l is a small perspective view of a cushion embodying the invention, and illustrating the fact that the cushion is conventional in appearance,V

Figure 2 is a sectionalrview on line 2 2 of Figure l, somewhat enlarged,

'Figure 3 is a similar view on line 3--3 of Figure l,

vFigure 4 is an enlarged fragmentary sectional view showing a portion of a plurality of layers of filler material and illustrating how such vmaterial is cut to form4 the core-receiving pocket, f i

Figure 5 is a similar view, substantially further .en-

.0f the larged, showing a singlejthickness of a portion of one ment is formed.

Referring to the drawing, the numeral 10 designates na core element as a whole formed of preferablyidentical sections il having normally iiat contacting surfaces provided y'with surface indentations *13 of substantial depth.` The indentations of the sections il' may register or not, Yand the indentations provide spaceswhich for increased deformability of the sections 11, thesel sections in themselves possessing a high degree of deformability for the reason thatthey are formed ofy foam rubber. The outwardlyv facing surfaces 1d of the sections limay be smooth and are convex transversely and longitudinallyof the cushionv as indicated in Figures 2 and 3. The core element 1t) is wholly surrounded by aiiller structure indicated as a whole by the numeral 15 .and formed of a plurality of layers of suitable loose fibrous material, for example cotton battingt in the present. instance, the filler 15 is shown as being formed of'six layers. It will be Vnoted that the vconvex formation of the surfaces 14 feathersfthe edges ofthe core element'l') and certain of the layers of filler material 15 have internal openings4 forming a pocket to receive the core element l@ shaped as stated. The two innermost layers'l of the filler 15 are provided with openings 17 (Figure 1) corresponding to the shape of the coreelement llland preferably slightlyl smaller than such element at the featheredl edge thereof. The next adjacent layerslA ofthe core structure are provided with smaller openings 19 (Figure 4) while kthe outermost layers 2i) of the liller structure are solid from edge to edge as shown in Figures 2 and 3.- The edges'17 and 19 will be somewhat deformed whenthe device is assembled, and they cooperate with the inner faces of the layers 2.6 to form a pocket y271 corresponding approximately in shape to', the core element 16 as sho-wn in Figures 2 and 3.A A

The layers 16, v18 and 20 preferably areloosely stitched therethrough as at 24 (Figure 5) and these stitches preferably extend perpendicular to each other in alternate layers, as suggested in Figure 6. lf desired, onlydthe outermostvlayers 20 need-be stitched, but it is preferred that the stitching be applied to all layers to increase the stability thereof by minimizing any tendency for the'layers to pull or stretch horizontally. lt is unnecessary to stitch each filler layer in both directions since the longitudinal stitching of alternate layers tends to prevent stretching ofthe entire filler structure parallel to the lines of'such maining layers tends to prevent stretching of the entire i i The two sections 11 of the core element may be readily i molded independently of each other,A and obviously they may be formed in the same mold. These sections are assembled by applying cement 2S to the contacting surfaces thereof, at least around the edge portions thereof. Thev core element thus assembled may be placed in the lower set of layers 16, l18 and 20, whereupon the upper layers 16, 1S and 2li may be successively placed in position. The unit thus formed then may be placed within va surrounding fabric, plastic or other suitable type of covering to form the nished cushion 30 shown in Figure 1. If desired, the binder material 26 may be applied to horizontal surfaces of the filler material and the binder for the edges of the layers may be applied after the assembly of the layers around the core element 10. This will tend to bind together the various layers and, in practice, it has been found that the unit thus formed, including the core velement and the iiller layers, possessesv a high degree of stability so that it may be shipped to furniture manufacturers as a unit to be embodied by them in covers 29 of their own selection.

In accordance with conventional practice, the top and bottom surfaces of the finished cushion bulge somewhat as in Figures 2 and 3. However, the core element 10 is more sharply convexed and thus provides the .greatestA core element depth, and consequently the highest degree of resiliency adjacent the center of the cushion where such resiliency is most needed. This arrangement also provides for the making of pocket openings 17 and 19 in certain of the layers to form the finished pocket 21, thus anchoring the core element 10 in its proper position within the cushion. The inished cushion has been found to provide a high degree of resiliency comparable with that of cushions employing spring cores, and the cushion is quite rugged and stable and will last for long periods f time without becoming deformed or misshapen.

I claim:

l. A core structure for a cushion comprising a plurality of layers of relatively soft ller material, the innermost layers being provided with relatively large openings therethrough and the next adjacent layers having relatively smaller openings therethrough to form an internal pocket within said ller material, and a core element of foam rubber corresponding generally in shape to and arranged in said pocket.

2. A core structure for a cushion comprising a plurality of layers of relatively soft ller material, the innermost layers being provided with relatively large openings therethrough and the next adjacent layers having relatively smaller openings therethrough to form an internal pocketv within said filler material, a core element of foam rubber corresponding generally in shape to and arranged in said pocket, and a coating of a flexible binder applied to the top and bottom surfaces of certain of said layers of filler material to add stability thereto.

3. A core structure for a cushion comprising a plurality of layers .of relatively soft filler material, the innermost layers being provided with relatively large openings therethrough and the next adjacent layers having relatively smaller openings therethrough to form an internal pocket within said iiller material, a core element of foam rubber corresponding generally in shape to and arranged in said pocket, a coating of a flexible binder applied to the top and bottom surfaces of'certain of said layers of ller material to add stability thereto, and stitching extending through at least the outermost layers of Asaid ller material and extending across each such layer in one direction to minimize stretching of each such layer vin such direction.

4. A core structure for a cushion comprising a plurality of layers of relatively soft filler material, the innermost layers being provided with relatively large openings therethrough and the next adjacent layers having relatively smaller openings therethrough to form an internal pocket within said filler material, a core element of foam rubber corresponding generally in shape lto and arranged in said pocket, a coating of a flexible binder applied to the top and bottom surfaces of certain of said layers of iiller material to add stability thereto, and stitching extending through at least a plurality of said layers including the outermost layers,.said stitching extending substantially throughout a horizontal dimension of each such layerin one direction to minimize stretching or pulling of said ller material.

`5. A core structure for a cushion comprising a plurality of layers of loose soft brous material, the innermost layers having relatively large openings therethrough and the next adjacent layers having relatively smaller openings, such openings cooperating with the surfaces of the layers of filler material outwardly thereof to form an internal pocket in said filler material, a core element of foam rubber corresponding generally in shape to and arranged in said pocket, and layers of a flexible binder bonded to a plurality of the surfaces of said layers ncluding the top surface of the top layer, the bottom surface of the bottom layer, and the outer edge surfaces of all of said layers.

6. An article constructed in accordance with claim 3 wherein a plurality of said layers, including at least the top and bottom layers, are loosely stitched therethrough along lines extending at least in one direction across each 'such layer to minimize longitudinal pulling of such layers along the lines of stitching.

7. AV core structure for a cushion comprising a body of a relatively soft deformable .fibrous ller material cut away to form an internal pocket, land a foam rubber core element corresponding generally in shape to and arranged in said pocket, said core element having substantially convexed top and bottom surfaces and the filler material adjacent the ycenter of such core element, without deforming, being relatively thinner than the iiller material adjacent the edge portions of said core element.

8. A core structure for a cushion comprising a plurality of layers of relatively soft material, the innermost layers being provided with relatively large openings therethrough and the next adjacent layers having relatively smaller Vopenings therethrough to form an internal pocket within said filler material, each layer of ller material having lines of stitching therethrough extending in one direction along each such layer, the ,lines of stitching of alternate layers being perpendicular to each other, and a core element of foam rubber corresponding generally in shape to and arranged in said pocket.

9. A core structure for a cushion comprising a plurality of layers of relatively soft material, the innermost layers being provided with relatively large openings therethrough and theA next adjacent layers having relatively smaller openings therethrough to form an internal pocket within said iiller material, each layer of liller material having lines of stitching therethrough extending in one direction along each such layer, the lines of stitching of alternate layers being perpendicular to each other, a coating of a ilexible binder applied to at least one horizontal surface of at least a plurality of said layersof liller material to add stability thereto, and a core element of foam rubber corresponding generally in shape to and arranged in said pocket.

l0. A core structure for a cushion comprising a plurality of layers of relatively soft iiller material, the innermost layers being provided with relatively large openings therethrough and the next adjacent layers having relatively smaller openings therethrough to form an internal 5 pocket within said ller material, and a core element of highly resilient material corresponding generally in shape t0 and `arranged in said pocket.

References Cited inthe le of this patent UNITED STATES PATENTS 752,147 Derick Feb. 16, 1904 1,211,548 Courts Jan. 9, 1917 1,928,568 Loomis Sept. 26, 1933 6 Dodge July 22, 1941 Blair Mar. 30, 1943 Lenz Feb. 6, 1945 West Oct. 9, 1951 Futterknecht Dec. 2, 1952 OTHER REFERENCES Home Craftsman Mag. pp. 20, 21 and 54, January- February 1951. 

1. A CORE STRUCTURE FOR A CUSHION COMPRISING A PLUMOST LAYERS BEING PROVIDED WITH RELATIVELY LARGE OPENINGS THERETHROUGH AND THE NEXT ADJACENT LAYERS HAVING RELATIVELY SMALLER OPENINGS THERETHROUGH TO FORM AN INTERNAL POCKET WITHIN SAID FILLER MATERIAL, AND A CORE ELEMENT OF FOAM RUBBER CORRESPONDING GENERALLY IN SHAPE TO AND ARRANGED IN SAID POCKET 